Manufacture of metallic soaps

ABSTRACT

METALLIC SOAPS OF GROUP II OF THE PERIODIC TABLE ARE PREPARED BY DISPERSING THE METAL OXIDE IN A HIGHER FATTY ACID AND MIXING THEREWITH 3.5 TO 40 MOLE EQUIVALENTS OF WATER BASED ON FATTY ACIDD. SURFACTANTS ARE USEFUL CATALYSTS FOR THE REACTION.

United States Patent ABSTRACT OF THE DISCLOSURE Metallic soaps of Group II of the Periodic Table are prepared by dispersing the metal oxide in a higher fatty acid and mixing therewith 3.5 to 40 mole equivalents of 25 Claims water based on fatty. acid. Surfactants are useful catalysts for the reaction.

This application is a continuation-in-part of cope nding application Ser. No. 840,503 filed July 9, 1969, now abandoned.

The present invention relates to a process for the manufacture of metallic soaps and in particular to metallic soaps prepared from metals in Group II of the Period Table and the higher fatty acids of from about 12 to about 22 carbon atoms which acids are known and sold to the industry as commercial fatty acids.'The commercial fatty acids ascommonly used are usually mixtures of higher fatty acids in wh'ic'h. the name attached to them may be only the dominant acid .of the mixture and in some grades of commercial stearic acid may not even be the acid present in the largest proportion. The most common soaps are those prepared from magnesium, calcium and zinc and have found wide application in commerce as waterproofing agents, thickening and suspension agents, lubricating and anticaking agents. They are also used as stabilizing agents for plastics, particularly polyvinyl chloride.

Metallic soaps of the higher fatty acids, the most common of ;which are the metallic stearates, are prepared by three principal types of processes.

(1) Double decomposition process A hot aqueous solution of the sodium salt of the fattyacid (prepared by reaction of the fatty acid and aqueous caustic) is reacted with a hot aqueous solution of the appropriate metal salt. The insoluble metal soap precipitate is filtered, washed free of soluble salt, dried and milled. By far the largest amount of commercial metallic soap of the Group II metals and particularly those known as stearates are produced by this process. By proper control of the temperature and dilution a product with a veryfine crystal size is obtained that is ideal for many applications. The preparation,'washing and drying operations are all expensive and time consuming and the material therefore inherently has a high production cost. The product is easily milled however.

(2) Reaction of metal oxides and hydroxides with molten fatty acids (a) Fusion process: The molten fatty acid is reacted with the appropriate metal oxide or hydroxide at a high temperature (l50-200 C.) to form-the metallic soap and water which is driven off at the high reaction temperatu're. The reaction requires from 3 to 5 hours for completion. This process is used extensively but produces a material which is hard and glassy in nature and is difiicult to grind toa fine particle size. It is principally useful where a. fine particle size and the surface characteristics of the metal soap are not responsible for its usefulness.

(b) Modified fusion process: A mixture of the liquid fatty acid and metal oxide is mixed with a very small amount of water. The reaction then takes place forming the metallic soap and the water which is formed is driven off in the process by the high temperature. This process. has the advantage of'a much lower reaction temperature. The initial temperature generally being in the range of to C. with a top temperature of from 100 to 200+ C. This process still produces, however, a material of a hard glassy nature that is difiicult to grind to a product that approaches the properties of Process No. l.

(c) Semi-fused or slurry process: The molten fatty acid is reacted with an aqueous slurry of the metal hydroxide or oxide (sometimes carbonates) during a period of over two or more hours to form the metallic soap. Considerable heat is required to drive off the excess water and complete the reaction. Lower temperatures are normally employed in this reaction due to the water present but it also produces a hard granular material which is also often difiicult togrind and has a high moisture content and therefore must be dried for a period of time before milling. This makes the process both time consuming and expensive.

(3) Metal-acid reaction process. In this process molten fatty acid is reacted directly with the metal yielding the metallic soap and hydrogen. This process is not used extensively in the preparation of metallic soaps from the metals of Group II of the Periodic Table and does not produce material of the desired physical characteristics for many applications.

There are other processes that can be employed for the preparation of metallic soaps from metals of Group II. However, the three mentioned are used to produce the great preponderance of material currently being manufactured commercially. In spite of the advantages in many applications of the product produced by the precipitation or-double decomposition process, considerable material is still produced by the fusion and modified fusion processes. This is a result of the lower cost of both the raw materials and the processing.

The modified fusion process was a major advance over the fusion process in the manufacture of metallic soaps involving metals of Group II. As indicated above it substantially reduce the initiation temperature for reaction and to a lesser extent also the maximum temperature attained, as well as a reduction intime to complete the reaction. The modified fusion process iscarried out by adding water, with stirring, to a mixture of fused fatty acid and metallic oxide or hydroxide. Reaction is initiated normally in the range of 90 to 100 C. It then goe through an exotherm and at the high oxide to fatty acid ratios usually employed in the process the reaction is 'often complete enough in 10 minutes to cool and mill. The amount of water added to the fatty acid-oxide mixture usually ranges between 1 and 1.5 mole-equivalents of water based on fatty acid or from 0.5 to somewhat over 1 mole-equivalents based on metal oxide employed. Extremes of 0.5 to 3 in both ratios have been claimed.

It has been discovered that by dispersing the finely ground metal oxides of Group II in molten higher fatty acids and mixing well therein from 3.5 to 40 mole-equivalents of water per mole-equivalent of fatty acid, products are obtained that are soft friable solids, low in free fatty acid and easily milled to give products with properties that approach those of precipitated metallic soaps in slip, texture and bulk. The reaction initiates rapidly and proceeds to completion in a minimum of time at temperatures that seldom exceed 110 C- and more usually 101- 105 C. in the final stages. These temperatures are significantly lower than the softening point of the metallic soaps being prepared. The moisture content, although higher than the modified fusion process, is low enough reactants.

In the preferred embodiment of the instant invention,

the metal oxide is dispersed in the molten fatty acid and the proper amount of water is thoroughly mixed into the dispersion mixture at a temperature between 90 and 135 C. The use of pressure in this portion of the reactor is required to insure proper mixing when temperatures above 100 C. are employed. While pressures above atmospheric can be employed during the entire reaction it is preferred to reduce the pressure to atmospheric before the reaction mixture solidifies. Temperatures as low as 55 C. may be employed to start the reaction. The time required for the initial vigorous reaction exotherm to start (induction time) however, is so much longer at the lower temperatures, that a temperature in the neighborhood of 90+ is preferred for commercial processing. Otherwie, means to reach this temperature in the reaction chamber should be provided to conserve time. The optimum moleequivalent ratio of water to fatty acid varies somewhat depending on the particular oxide and fatty acid employed, and to some extent also on the ratio of metallic oxide to fatty acid. In general the process is operable in the range from 3.5-1 to at least 40-1 mole-equivalents of water to fatty acid. The preferred ratio, in order to obtain optimum properties, however, is in the range of 5-1 to 40-1 for most of the oxides. The higher ratio of water, although producing a satisfactory product, is uneconomical except where high moisture content is desired such as in the production of aqueous suspensions since thte remval of the excess moisture is very costly. There is little improvement in the properties of the products after a ratio of approximately -1 is reached. The practical range of ratios preferred for commercial operation where the product is to be milled is the range from 6-1 to -1 and more usually 6-1 to 12-1. It is an essential part of this process that the metal oxide first be dispersed in the fatty acid and then the water added. Dispersal of the oxide in the water prior to its addition to the fatty acid gives a product with entirely different characteristics to that obtained in the process of instant invention and one with a much longer reaction time.

The metal of Group II of the Periodic Table are generally applicable in instant process. However, the oxides of barium, calcium, cadmium, magnesium, strontium and zinc lend themselves particularly well to this process. The oxides of calcium, magnesium and zinc are the preferred oxides in the process, which is fortunate, since they have the greatest commercial value. It is important that the proper oxides be utilized to obtain the best results. The finer the particle size of the metallic oxide and the better the dispersion in the fatty acid, the more rapid and uniform is the reaction, and the better the quality of the metallic soap produced. In general a coarse oxide or one that is poorly dispersed (although there is some dependence on the particular oxide involved), either will not react well or will produce a product with a high free fatty acid, particularly at low oxide to acid ratios. Simple mixing of the metal oxide into the fatty acid has been found to greatly extend reaction time required and to give a poorer product than is obtained by thorough dispersion.

It has been found that the surface condition of the oxide has a large effect on the rate of reaction. For instance, American process zinc oxide dispersed in a fatty acid reacts extremely rapidly with the fatty acid on the introduction of water. However, French process zinc oxide tends to react very slowly initially under the same conditions. In many cases it is important to have a long pot life of the metal oxide-fatty acid dispersion and since the pot life is extended greatly by utilizing French process zinc oxide in place of the American process oxide, a catalyst must be utilized to obtain equivalent reaction speeds. Soluble salts of zinc, such as zinc nitrate, sulfate and chloride, nitric and acetic acid, sodium and potassium hydroxide all have shown some catalytic activity in accelerating the rate of reaction of fatty acids with metal oxides in the instant process. Surface active agents (surfactants), however, have been found to be the most effective catalysts.

Anionic, cationic and nonionic surfactants all act as catalysts and accelerate the reaction. Catalytic activity however, varies considerably from compound to compound. Surface active agents found to be active include: alkanolamides, ethoxylated alcohols, ethoxylated alkyl phenols, ethoxylated amines and amides, ethoxylated fatty acids, ethoxylated fatty esters, faty acid esters (including esters of glycol and glycerol), fluorinated fatty aid salts, tertiary amine oxides, lecithin and derivatives, phosphate esters and other derivatives, quaternary ammonium compounds and sorbi-tan derivatives. The most active compounds have been the sulfonates, sulfates and related compounds. Examples of the latter are: alkyl sulfonates, sulfated and sulfonated amines and amides, isethionates, alcohol sulfates, ethoxylated alcohol sulfates, sufonates of benzene, naphthalene, diphenyl, diphenyl ether and their alkyl derivatives, condensed naphthalene sulfonates, fatty acid and natural oil sulfonates and sulfates, petroleum sulfonates and taurates.

Exceedingly small concentrations of the more active sulfates and sulfonates greatly accelerate the instant reaction. Concentrations as low as 0.001% based on fatty acid, increase the reaction rate significantly. As the concentration of surfactant is increased the rate of reaction increases also. Concentrations as high as 5% are effective. At these high concentrations the surfactant may adversely affect the surface properties of the metallic soap produced for some uses and thus concentrations in the range from 0.01 to 1.0% are preferred with concentrations in the range from 0.02 to 0.5% the most common. The latter ranges give good rates without adverse effects on the physical properties of the product.

It has been found that the catalytic action of the surfactants is not limited to the process of the instant invention but is effective for the entire range of mole-equivalnt ratios of water to fatty acid from 0.5 to 40 and operative range of ratios of metal oxide to fatty aid.

The catalytic activity of the surface active sulfonates, sulfates and related compounds is exhibited by the reduction of the induction time for the reaction with zinc and cadmium oxides or by the reduction of the free fatty acid concentration as with the calcium and magnesium oxides. With calcium and magnesium oxides the reaction appears to be rapid and vigorous without a surfactant but a catalyst is required if a low free fatty acid content is desired in a short reaction time.

The cation associated with the sulfonate or sulfate is not critical as long as it forms a salt with the anion that has reasonable solubility in water at the reaction temperature. Thus ammonium, sodium, potassium, calcium and magnesium salts are operative. The surfactant can be incorporatedin either the water or fatty acid dispersion. It is commonly incorporated in the water. Examples of anions giving exceptional activity are: dodecyl and tridecyl benzenesulfonates, dodecylnapthalene sulfonate, dodecyldiphenyl ether disulfonate, dodecyl to heptadecyl sulfates, octylphenoltetraethoxy sulfate, dioctyl ester of sodium sulfosuccinic acid, dodecyl ester of sodium isethionate, potassium N-methyl-N-oleoyltaurate and Post 4 (a product of the Baker Castor Oil Company). These are typical only. The alkyl groups can be straight chain or branched. The groups that give good surface activity are well known in the art and have been extensively researched. Thus Z-ethylhexyl sulfate which is not highly surface active is not as active a catalyst as dodecyl ortetradecyl sulfates which are surface active. The classification of surfactants and identification is given in McCutcheons Detergents and Emulsifiers Annual," John W. McCutcheon, Inc., Morristown, NJ. Reference is also made to Surface Chemistry" by Osipow A.C.S. Monograph Series No. 153, and Emulsions Theory and Practice by Becher, A.C.S. Monograph Series No. 162, Reinhold Publishing Company.

A wide range of fatty acids can be employed. Lauric, myristic, palmitic, stearic, arachidic and behenic acids all work very well as do their mixtures obtained commercial ly. In their relatively pure state the unsaturated fatty acids such as oleic and pal-moleic acids have not been found to react as readily as the saturated acids, often giving products that are hard to handle or incompletely reacted. The amounts found in commercial single pressed and triple pressed stearic acid, tallow fatty acid and hydrogenated tallow fatty acids as well as hydrogenated fish fatty acid, coconut fatty acid and others have not presented any difficulty and have operated well. The term higher fatty aids as used herein refers to those predominantly saturated fatty acids and including C to C and their common commercial mixtures. For ease in processing, the fatty acids should be free from contaminants that will react prematurely with the metallic oxide prior to the addition of the water or that will catalyze the metal oxide to fatty acid reaction during the initial mixing. As described above, there are a number of compounds which appear to exercise a degree of catalysis on the reaction of Group II oxides with the fatty acids particularly in the presence of water. It has been found that some of the low grade commercial fatty acids such as that commonly called rubber grade stearic acid and which normally contain large quantities of impurities are sometimes difficult to utilize in the process of the instant invention due to their premature reaction with the metal oxides. A considerable variation in the rate of reaction of various commercial fatty acid compositions with the metallic oxides has been observed. Since most commercial fatty acids are from natural product sources, some variation is to be expected. This has presented no problems.

The maximum temperature obtained during the bulk of the reaction may go as high as 115 C. in isolated cases processing. The metal oxide-fatty acid dispersion is either prepared continuously or in batches as the dispersion has a long potlife with most oxides. The water, usually containing a surfactant, is mixed continuously with the fatty acid dispersion. The dispersion and water are either heated before mixing or after mixing to initiate the reaction. After the reaction is initiated it is continued in the neighborhood of 100 C. until the desired free fatty acid concentration is obtained. The product is commonly milled without cooling. When the temperature of the initial reaction is raised to obtain shorter induction and reaction time, the ratio of water to fatty acid must also be raised to provide sufficient cooling to prevent fusion of the product. A significant feature of the continuous process is that the product can be milled hot due to its physical form avoiding delays and further processing.

As used herein, the term mole-equivalent as applied to water refers to an equivalent weight of 8. Metals of Group II of the Periodic Table refer to the metals beryllium, calcium, magnesium, zinc, strontium, cadmium and barium. Surfactants employed as catalysts can be added with either ingredient or separately such as with the actylenic alcohols which show mild catalytic activity. The term ethoxylated alcohol sulfates include sulfates of ethoxylated alkylphenols as well as ethoxylated alkyl alcohols and other similar compounds.

It should be noted when comparing rates of reaction from free fatty acid content that a correction must be made for the efiect of temperature on the reaction.

The invention will be further described by reference to the following examples which set forth the specific embodiments of the present invention. These embodiments however, are merely illustrative and not to be construed as limitative of the present invention.

EXAMPLE 1 Zinc oxide was dispersed in a molten commercial hydrogenated fatty acid (200 g.) In the molecular ratio indicated at 95 C. Water (98 C.) was introduced in the molecular ratio indicated and thoroughly mixed in. After 10 minutes the product was removed, air dried and milled once on a Pulverizing Machinery laboratory hammer mill. The apparent density of the milled product was determined with Scott Volumeter.

Mole-equiv. ratio Oxide} Water] Peak Time to Apparent fatty fatty temp., exotherm, density, Fatty acid Oxide acid acid 0. min. g./cu./in. 1. 2:1 1. 0:1 124 12 5. 94 1.21 2.021 110 2.7 4.96 1.221 2.511 108 1.6 4. 69 1. 2:1 3. 0:1 107 1. 3 4. 65 1. 2:1 4. 0:1 105 1 4. 34 1.231 5.0:1 105 1.2 4.18 1.2:1 7.0:1 104 0.4 3.64 1.2:1 4.0:1 3.68 1. 2:1 7. 021 3. 19 1.221 5.0:1 3. 52

Capryllc acid (95%). 1. 2:1 Reacted before water could he added Laurie acid. (95 o Calcium 1. 4:1 8.0:1 106 3. 11 Fish fatty d 4. 86 Precipitated zinc 2. 55

stearate.

l Hydrogenated tallow fatty acid. 1 Commercial double pressed stearic acid.

but is generally below 110 C. and usually below 105 C. EXAMPLE 2 While the reaction proceeds very rapidly at the higher mole-equivalent ratios (2 to 1 and above) of metal oxide to fatty acid, it also proceeds rapidly and to completion at lower ratios of the order of 1.2-1.05 to 1. At very low mole-equivalent ratios (of the order of 1 to l and lower, metal oxide to fatty acid) longer reaction times are required with some oxides in order to obtain a product with a low free fatty acid. Below a ratio of 1 to 1 the free fatty acid increases as expected. Ratios as low as 0.5

to 1 can be employed.

Calcium oxide was dispersed in a molten commercial hydrogenated fatty acid (1 kg.) in the mole ratio of 1.2:1 at 90 C. Water (90 C.) was introduced in the mole ratio indicated and thoroughly mixed in. When the reaction product had cooled it was air dried and milled once on a Pulverizing Machinery Company laboratory hammer mill. The apparent density of the milled product was determined with a Scott Volumeter. Samples were taken at 10 minutes and cooled in sealed containers. These were The instant process is readily adapted to continuous dried and the moisture content determined.

Apparent Moisture Mole-equivalent density, content, ratio Water/FA g./cu. in percent EXAMPLE 3 Calcium oxide was dispersed in 1 kg. of molten hydrogenated tallow fatty acid at 90 C. (1.2 mole-equiv. ratio oxide to fatty acid) and water (90 C.), in sufficient quanten fatty acid (200 The following metal oxides were dispersed in the molg.) and method of Example 1.

Mole-equiv. ratio Additional Metal Water temp., oxide/FA FA 0. Comment sro 1. 1:1 7. 5:1 87 No reaction took place until water added, than 1. 5:1 7. 5:1 immediate vigorous reaction. Bao 1.111 4.011 87 Reaction took place shortly after addition of ""i 1. 5:1 7. 5:1 oxide. Water must be added immediately to the dispersion to obtain proper reaction. Gd 1 2:1 1 10:1 90 No reaction took place until water added. Mixture took 13 min. to begin vigorous exotherm. MgO 1. 16:1 7. 5:1 55 No reaction took place until water added then immediate vigorous reaction.

1 Orvus AB added (0.4 g).

tity to give the following mole-equiv. ratios, was added. Stirring continued seconds.

EXAMPLE 8 Zinc stearate was prepared as in Example 1 with a Time to Time to peak of Peak Mill- Mole-equiv. ratio exotherm, exotherm, temp., Percent able water/fatty acid sec. mi FFA Product state (10 min.) hot 3.5 137.5 8.8 Sticky, plastic mass No. 30 5 130 4.2 do No. 25 6 115.5 4.8 Foamy, sticky plastic mass No. 20 11 112 5. 2 Foamy, semiplastic 20 11 108 6.8 Soft, friable solid at 5 min. 20 1.8 102 d0 20 1 101 Yes 210 1 101 20 1 101 20 1 101 EXAMPLE 4 Metallic stearate was prepared as in Example 1 at 90 C. and passed twice through the laboratory hammer mill. A mole-equiv. ratio of 1.2:1 metal oxide to commercial hydrogenated tallow fatty acid was employed.

Metallic stearates were prepared as in Example 1 in the ratios given below from a commercial stearic acid.

Mole-equiv. ratio Free Oxide] Water/ fatty acid, Metal oxide fatty acid fatty acid percent EXAMPLE 6 A commercial double pressed stearic acid was reacted with metallic oxide and water as in Example 1 at 93 C.

mole-equiv. ratio of water to fatty acid of 7521 only the water was added at various temperatures and the time to reach C. noted.

EXAMPLE 9 (a) 34.4 g. of powdered zinc oxide (French process) was dispersed in 200 g. of hydrogenated tallow fatty acid and the temperature maintained with stirring at 100 C. for 5 hours. No change in viscosity was observed.

(b) The process of (a) was repeated with American process zinc oxide. After three hours the mixture thickened and underwent an exothermic reaction.

(c) The materials of (a) were heated for 5 minutes at 100 C. then cooled, allowed to solidify and stand for 48 hours then reheated and maintained at 100 C. for 3 hours. No change was observed.

(d) The process of (a) was repeated with 20.8 g. of finely powdered calcium oxide. No change was observed.

9 EXAMPLE 1o 68.6 g. zinc oxide (American process) was dispersed in 400 ml. water and heated to 95 C. This slurry was acid (400 g.) and 4:1 water to fatty acid starting with fatty acid zinc oxide dispersion and water at 96 C. Fatty acids and zinc oxides as indicated were employed.

Zinc Additive Time to Peak Fatty acid oxide to water exotherm temp.

Hydrogenated tallow FA.

Do Do--. Do 0.2 g. NaOH Do 0.2 g. acetic acid..." 2 min. Do do- 0.1 g. Triton 100 1.5 min. D0.- .do 0.05 g. SDBS I 1 min. 109 Do do 0.10 g. SDBS I 30 sec. 110 Humko 4516 N 5 see. 110 Double pressed dn dn 5 min. 106

Additive to fatty acid Hydrogenated tallow FA do 2 g. oleic acid 1 min. 103

1 Product of Rhom & Haas Company. 1 Sodium dodecylbenzene sultonate.

added to 400 g. of molten commercial hydrogenated fatty acid at 95 C. with vigorous stirring. (A paddle stirrer driven by an air motor was used.) The temperature slowly rose to 100 C. minutes), when steam began to be evolved. The reaction mixture was held for minutes, then cooled and dried.

FFA=15% The same amounts of reactants and same temperature were used. The zinc oxide was dispersed in the water in an Osterizer. The slurry was then added to the molten acid in the Osterizer while mixing at the highest speed. Steam began to be evolved within 15 seconds and temperature reached 108 C. After 10 minutes the product EXAMPLE 12 Continuous preparations of metal stearates were made by pumping a 1.2 to 1 mol-equiv. ratio dispersion of metal oxide in molten commercial stearic acid into a pressurized mixing chamber along with the mole-equiv. ratio of water containing Orvus AB 1 in the concentration specified below, heated to 100 C. After passing through the pressurized mixing device it was discharged at atmospheric pressure, into a mixer conveyor with a stay time of 3.7 minutes. Copious amounts of steam were evolved durwas cooled and ing the reaction. Where possible, the product was milled FFA=12% hot as it discharged from the mixer conveyor.

Water: Percent Mixing Free fatty acid detergent temp Product form aci Metal oxide ratio in water C. on discharge percent 4:1 0.113 Granular,M 0.8 4:1 0.113 125 Plastic, lumpy, U 8:1 0.113 125 Soit,iriable,M 0.40 10:1 0.113 125 .do 0.38 4:1 None 125 Semlplastic, 10:1 None 125 Soft, friable, M 5 9 10:1 0.3 d 2.5 10:1 0.3 2.0 8:1 0.3 2.1

No'rE.-U=Unmilleble hot; M=Mi11able hot.

EXAMPLE 13 EXAMPLE 11 Zinc oxide (177.5 g.) (French process) was dispersed The process of Example 1 was carried out with zinc oxide at a mole-equiv. ratio of 1.2 metal oxide to fatty in 1 kg. of molten hydrogenated tallow fatty acid at Gamble-40% sodium dodecyl- A product of Procter and benzene sulfonate.

Active ingredient,

percent Induction Surfactant time 7 min.

2 min. 30 sec. 4 min. 40 sec. 40 sec.

4 min. sec. 6 min. 30 sec. 5 min. 45 sec. 3 min. 30 sec. 3 min.

6 min.

5 min. 30 scc. 4 min. 35 sec. 4 min. 30 sec. 3 min. 55 sec. 4 min. 5 sec. 3 min. see. 6 min. 40 sec. 6 min.

3 min. 25 sec. 3 min. 5 sec. 3 min. sec. 2 min. 30 sec.

Post 4 Surfactol 666.

3 min. 3 min. 3 min. 30 sec. 2 min. 45 sec. 3 min. sec. 5 min. 10 sec. 3 min. sec. 4 min. 10 sec. sec. 2 min. sec. 1 min. 40 sec. 53 sec. 1 min. 10 sec. 1 min. sec.

Gafao RM-Slo. 3 min. 24 sec. Nacconol 90-11. 90 22 sec. Oivus AB 40 30 sec. Conco .AAS-JO... 85-90 27 sec. Coneo Arts-90 85-90 35 sec. Benox 2A1 90 45 sec. 'Icigit 7 27 1 min. 45 sec 27 sec. 40 1 sec. 45 sec. r 28 2min. 10 sec. Victawct 70 3 min. 10 sec. Maprofix Powder LK 9O 50 sec. Calcium dodecylbenzenesulfonate.-. 100 40 sec. Dowfax 9N9 100 6 min. Sulfricin 100 3 m'n. 22 sec. Fluorochemical FC-128--. 100 5 min. 54.. Zinc sulfate (2 g.) 100 5 min. Alkanol 189$ 1 min. 10 sec.

Surfactant manufacturer Surfactant chemical structure Swift & Company Oleic ester of polyethylene glycol. Emery Industries Coco monoethanolamide. Baker Castor Oil Company. Sulfonated castor 011 derivative.

.do Ethoxy propoxy castor oil. .60 Ethoxylated castor oil. as Chemical Industries Sorbitan sesquioleate. -....do- Polyoxyethylene sorbitan triolcatc.

9 ..do. Polyoxyethylene sorbitan monostearate.

1O .do Polyoxyetliylene sorbitan monolaurate.

11 do..-.. Sorbitan monolaurate.

12- Airco Chemica Acetylenic glycol blend.

13 ..do. Do.

. 2,4,7,9-tetramethyl-5-decyne4fldiol. Do. Ethoxylated #14. Do. .do Dimethyloetynediol.

Wyandotte Chemicals Corp. Ethoxylated polypropylene glycol.

Swift & Company Modified amide.

21 .do Unknown.

22. Witco Chemical Company. Polyoxyethyleneesters of mono and dicarhoxylic acids plus oil soluble suifonates.

23 do. Unknown.

24"-.. do Do.

25- Rohrn a d Haas Company.. Sodium salt of condensed naphthalene sulfcnic acid.

26 .do Sodium salt of polymeric carboxylic acid.

27- Armour Industrial Chemi- N-alkyl tiimethyl ammonium c Co. chloride.

28- Onyx Chemical Company..- Alkyl dimethyl naphthyl-methylammonium chlorides. 29.-.. Rohm and Haas Company.. POtflSSllDl salt phosphate compoun 30- American Cyanamide Tetiasodium N-(1,2-dicarboxyethyl)-N-0ctadecy1sulf0si1ccinamate. I

31 ..do Dioctyl ester of sodium suliosuccinic acid.

Surfactant manufacturer Surfactant chemical structure 32. General Aniline and Film Sodium salt of sulfonated naph- Corp. thalene-formaldehyde condensate.

33 ..do Sodium N-metliyl-Nolcoyltaurate.

34 do Ammonium salt sulfatcd linear primary alcohol ethoxylatc.

35 do Ammonium salt of sulfate ester 0 ethoxylatcd alkyl phenol.

36 ..do Coconut-oil acid ester of sodium isethionate.

37 ..do Sodium alkylnaphthalcne sulfonate.

38 .do Acids of complex organic phosphate esters.

39- Allied Chemical Alkyl aryl sulfonate.

0.... Procter & Gamble Sodium linear alkylaryl sulfonate 41.-.. Continental Chemical Sodium dodecylbenzene sulfonatc- Company.

42 ..do Do.

43- Dow Chemical Company.-- Sodium dodecyldiphenylethcr disuifonate.

44. Union Carbide Corporation- Sodium 5,1l-diethyltridccan-S-ol sulfate.

45 .do Do.

. Sodium 2-ethyl-1-hcxylsulfate.

Sodium 5-ethyl-l0-methyl-undecane-5-ol sulfate.

48.... Staufier Chemical Com- (Na)5(2-ethyiliexyi) (1iO l0)2- pany. 49. Onyx Chemical Company.-- Sodium lauryl sulfate. 50.-.. Laboratory preparation Calcium dodecylbenzenesulfonate 51.... Dow Chemical Company... Oxyethylcnated nonylphenol. 52- Baker Castor Oil Unknown. 53- Minnesota Mining and Fluorochemical surfactant.

Manufacturing.

54---- Commercial Chemical 55- EkLCdu Pont de Nemours Sodium hydrocarbon sulfonate.

l Surfactant added to fatty acid.

EXAMPLE 14 French process zinc oxide was reacted with commercial hydrogenated tallow fatty acid (1 kg.) in the method of Example 1 in the mole-equivalent ratio of 1.221, and a water to acid ratio of 10:1. Orvus AB in the amount specified was dissolved in the water at C. prior to its addition to the acid-oxide mixture at 95 C. Detergent as per- Induction cent of acid: time, min. None 7 .001 5 3.5

EXAMPLE 15 The reaction of the metal oxides indicated with the fatty acid indicated and water was carried out in the stated mole equivalent ratios according to the procedure described in Example 13.

2 Same as footnote 1, Example 12.

Mole-equiv. ratio Induction time Fatty acid Oxide Oxide/FA Water/FA Surfactant Percent minutes 1.2:1 3:1 Non 4.0 1.21 3:1 Orvis AB 0. 1 0. 9 1.221 2:1 4.3 1.221 2:1 1 0.85 1.2:1 1:1 3.7 1.211 1:1 0.1 0.85 1.221 1:1 do.... 0. 01 3.0 1. 2:1 1:1 Sepan LS 2 0. 1.65 1.211 0.5:1 None 5.7 1. 2:1 0. 5:1 Orvis AB 0. 1 0. 8 1:1 3:1 No 5.0 1:1 3:1 Orvis AB 0. 1 0.8 2:1 1:1 None 1.6 2:1 1:1 Orvis AB 0. 05 0. 7 2:1 3:1 Nekel BA-75 0. 1 0. 5 2:1 3:1 Igepon T-77 0. 1 0. 6 2:1 3:1 lgeponAP-78 0.1 1.2 2:1 3:1 Calcium dodecylbenzene sulfonate 0. 1 0. 4 2:1 3:1 Nacconol 90F 0.1 0.4 2:1 3:1 Sodium dodeoylbenzene sulionate 0. 1 0. 4 2:1 3:1 Sodium lauryl sulfate 0.1 0.4 2:1 8:1 Aerosol 0'1 9 0.1 1.0 2:1 3:1 Tergitol TOL Anionic 7 0. 1 1. 2 2:1 2:1 N 0.5 2:1 2:1 Orvis AB 0.1 0.2 2:1 2:1 .do 0.025 0.2 2:1 2:1 0.15 2:1 2:1 0.1 0.05 1.2:1 1.5:1 0.3 1.2:1 1.511 0.1 0.1 1. :1 1.5:1 1. 4 1. 15:1 1.5:1 0.05 0. 6 1.15:1 1.511 0.01 11 1.1 1. 15:1 1. 5:1 0.05 1. 1 1.15:1 1.5:1 Igepon 'l77 0.05 11 0.4

For footnotes see the following table:

Percent active ingredient Suriactant,-ehemical Surfactant manufacturer it known structure, it known Procter& Gamble Sodium linear-alkylaryl sultonate.

( Sepan Gener 65 Sodium alkylnaphthalene sulionate. do 67 Sodium N-methy1-N-oleoyl tour a. 83 Coconut oil acid ester of sodium isethionate. 3g Alkylaryl sulionate. Onyx Chemical Co. 90 American Cyanamid 100 Tetra sodium N (1,2-dicarbethoxyl)-N-octodecyl sultosuccinamate. Union Carbide 27 Sodium 5, ll-diethyltridecan- 8ol sulfate. Reaction temperature 54 C. We claim: 9. The process of preparing metallic soaps comprising The Process of P p metanlc Soaps compflsmg dispersing modes of metals of Group II of the Periodic dlspefsfflg OXldeS of {metals of 0? 0 PCTIOQMC 0 Table in a molten higher fatty acid, mixing water with Table in a 010 1 hlghef fatty acid, 1111x1118 l f said dispersion in a range of about 0.5 to 40 mole-equivalsald 1151361310111 "2; ti f2: f PtP f t l lents per mole of fatty acid, initiating the reaction at a ems P t mo b 5 52 E 113 30225 fg i g to temperature above 55 C. and allowing said mixture to tempera ure a (We a a g S 1 react in the presence of a minor portion of surface active react, the temperature of the final stages being below the 55 softening point of the metallic soap.

2. The process of claim 1 in which the metals of Group II are selected from the group consisting of calcium, magnesium, Zll'lC, cadmium, strontium and barium.

3. The process of claim 2 in which the proportion of sulfonates or sulfates.

10. The process of claim 9 in which the mole-equivalent ratio of water to fatty acid is from 3.5 to 40 and the temperature of the final stages of the reaction is below the softening point of the metallic soap.

water to fatty acid is in the range of 6 to 40 mole-equiva- The Process of claim 10 in Which e C ntralents of water per mole of fatty acid. tion of surfactant is from 0.001% to 5% based on fatty 4. The process of claim 3 in which the metals of Group acid- II are selected from the group consisting of: calcium, 12. The process of claim 11 in which the surfactant is magnesium and zinc. selected from the group consisting of: a water soluble 5. The process of claim 4 in which the proportion of salt of a surface active alkylarylsulfonate, alkyldi henyl water to fatty acid is in the range of 6-15 mole-equivaether disulfonate, alkyl sulfonate, alkyl sulfate, sulfate of lcnts of water per mole of fatty acid. cthoxylatcd alcohol and alkylphenol, isethionate, taurate, 6. The process of claim 5 in which the proportion of sulfated and sulfonated natural oil, sulfosuceinate ester.

Water to fatty acid is in the range of 6-12 mole-equiva- 13. The process of claim 13 in which the metal oxide lents of water per mole of fatty acid. is selected from a group consisting of calcium, magnesi- 7. The process of claim 6 in which the metal of Group urn, zinc, strontium, barium and cadmium.

II is calcium. 14. The process of claim 14 in which the metal oxide 8. The process of claim 6 in which the metal of Group 5 is selected from the group consisting of calcium, mag- I1 is zinc. nesium and zinc.

15. The process of claim 14 in which the surfactant is selected from the group consisting of water soluble salts of dioctyl sulfosuccinate, dodecylbenzenesulfonate, alkylnaphthalene sulfonate, dodecyldiphenyl ether disulfonate, Post 4, dodecyl to heptadecyl sulfates, dodecyl ester isethionate, N-oleoyl-N-methyl taurate, octylphenoltetraethoxy sulfate.

16. The process of claim 9 in which the metal oxide of Group II is selected from the group consisting of zinc, calcium and magnesium.

17. The process of continuously preparing metallic soaps of metals of Group II of the Periodic Table which comprises continuously mixing a dispersion of the metallic oxide in a higher fatty acid with about to 15 moleequivalents of water per mole of fatty acid, said water being in sufficient quantity to prevent fusion of the product on completion of the reaction, initiating the reaction at over 55 C., allowing the reaction to proceed and continuously milling the product as produced.

18. The process of continuously preparing metallic soaps of metals of Group II of the Periodic Table which comprises continuously mixing a dispersion of the metallic oxide in a higher fatty acid with about 3.5 to 15 moleequivalents of water per mole of fatty acid, said water being in sufficient quantity to prevent fusion of the product on completion of the reaction, initiating the reaction at over 55 C. in the presence of a minor portion of surface active sulfonates or sulfates and continuously milling the product.

19. The process of claim 18 in which the oxide of a metal of Group II is selected from the group consisting of: calcium, magnesium, zinc, strontium, cadmium and barium.

20. The process of claim 1.8 in which the oxide of metal of Group II is selected from the group consisting of calcium, magnesium and zinc.

21. The process of claim 20 in which the concentration of surfactant is between 0.001 and 5.0% by weight based on fatty acid.

22. The process of claim 21 in which the reaction is initiated between 90 and 135 C.

23. The process of claim 22 in which the mole-equivalent of Water per mole of fatty acid is between 6 and 12.

24. The process of preparing zinc soaps comprising dispersing zinc oxide in a molten higher fatty acid, mixing water with said dispersion in a range of about 4 to mole-equivalents per mole of fatty acid, initiating the reaction at a temperature above C. and allowing said mixture to react, the temperature of the final stages being below the softening point of the metallic soap.

25. The process of continuously preparing zinc soaps which comprises continuously mixing a dispersion of the zinc oxide in a higher fatty acid with about 4 to 15 moleequivalents of water per mole of fatty acid, said water being in sutficient quantity to prevent fusion of the product on completion of the reaction, initiating the reaction at over 55 C., allowing the reaction to proceed and continuously milling the product as produced.

References Cited UNITED STATES PATENTS 2,890,232 6/1959 Rogers et al. 260--414 3,519,571 7/1970 Szczepanek et al. 260-414 X OTHER REFERENCES 698,963 10/1953 Great Britain 260--413 LEWIS GOTTS, Primary Examiner E. G. LOVE, Assistant Examiner US. Cl. X.R. 

